Dialysis continuous process for ammonium lactate fermentation: Simulated prefermentor and cell-recycling systems

A generalized mathematical model, previously developed and experimentally validated, was modified and used to computer-simulate the outcomes of adding two systems for increasing the concentration of cell mass in the fermentor, and thereby the rate and extent of substrate conversion, in a dialysis continuous process for the ammonium lactate fermentation of deproteinized whey. The addition of a nondialysis continuous prefermentor would not improve the process. However, the addition of cell retention time would be reduced ninefold, and the extent of converting substrate to product would be increased 25% and accomplished almost entirely by maintenance metabolism.     

Increased stress tolerance of Bifidobacterium longum and Lactococcus lactis produced during continuous mixed-strain immobilized-cell fermentation

AIMS: The effect of immobilization and long-term continuous culture was studied on probiotic and technological characteristics of lactic acid and probiotic bacteria. METHODS AND RESULTS: A continuous culture in a two-stage system was carried out for 17 days at different temperatures ranging from 32 to 37 degrees C, with a first reactor containing Bifidobacterium longum ATCC 15707 and Lactococcus lactis subsp. lactis biovar. diacetylactis MD immobilized separately in gel beads, and a second reactor operated with free cells released from the first reactor. The tolerance of free cells from both strains produced in the effluent medium of both reactors to hydrogen peroxide, simulated gastric and intestinal juices, antibiotics and nisin, and freeze-drying markedly increased with culture time and was generally higher after 6 days than that of stationary-phase cells produced during free-cell batch fermentations. The reversibility of the acquired tolerance of B. longum, but not L. diacetylactis, to antibiotics was shown during successive free-cell batch cultures. CONCLUSIONS: Free cells produced from continuous immobilized-cell culture exhibited altered physiology and increased tolerance to various chemical and physico-chemical stresses. SIGNIFICANCE AND IMPACT OF THE STUDY: Continuous culture with immobilized cells could be used to produce probiotic and lactic acid bacteria with enhanced technological and probiotic characteristics.     

Solid-state fermentation: a continuous process for fungal tannase production

Truly continuous solid-state fermentations with operating times of 2-3 weeks were conducted in a prototype bioreactor for the production of fungal (Penicillium glabrum) tannase from a tannin-containing model substrate. Substantial quantities of the enzyme were synthesized throughout the operating periods and (imperfect) steady-state conditions seemed to be achieved soon after start-up of the fermentations. This demonstrated for the first time the possibility of conducting solid-state fermentations in the continuous mode and with a constant noninoculated feed. The operating variables and fermentation conditions in the bioreactor were sufficiently well predicted for the basic reinoculation concept to succeed. However, an incomplete understanding of the microbial mechanisms, the experimental system, and their interaction indicated the need for more research in this novel area of solid-state fermentation.     

Acid hemicellulose hydrolysates: Physical treatments and continuous immobilized-cell fermentations

Hardwood hemicellulose acid hydrolysates, enriched in pentoses through countercurrent operations, have been fermented by Pachysolen tannophilus NRRL Y2460 in batch reactors. In order to evaluate the effects of pentose as well as inhibitor concentrations on the overall ethanol yield, several materials have been used for the physical treatment of this hydrolysate: Fly ash, a mixture of ionexchange resins, a porous material constituted by SiO₂ and Al₂O₃ and a mixture of organic solvents. The best combination, consisting of an overliming pretreatment followed by a secondary treatment in a column filled with the Si-Al material, has assured an increase in ethanol concentration of 15%. Finally, the data of continuous fermentations of these hydrolysates in an immobilized-cell reactor are presented and discussed.     

Immobilized yeast cell systems for continuous fermentation applications

In several yeast-related industries, continuous fermentation systems offer important economical advantages in comparison with traditional systems. Fermentation rates are significantly improved, especially when continuous fermentation is combined with cell immobilization techniques to increase the yeast concentration in the fermentor. Hence the technique holds a great promise for the efficient production of fermented beverages, such as beer, wine and cider as well as bio-ethanol. However, there are some important pitfalls, and few industrial-scale continuous systems have been implemented. Here, we first review the various cell immobilization techniques and reactor setups. Then, the impact of immobilization on cell physiology and fermentation performance is discussed. In a last part, we focus on the practical use of continuous fermentation and cell immobilization systems for beer production.     

Dry-grind process for fuel ethanol by continuous fermentation and stripping

Conversion of a high-solids saccharified corn mash to ethanol by continuous fermentation and stripping was successfully demonstrated in a pilot plant consuming 25 kg of corn per day. A mathematical model based on previous pilot plant results accurately predicts the specific growth rate obtained from these latest results. This model was incorporated into a simulation of a complete dry-grind corn-to-ethanol plant, and the cost of ethanol production was compared with that of a conventional process. The results indicate a savings of $0.03 per gallon of ethanol produced by the stripping process. The savings with stripping result from the capacity to ferment a more concentrated corn mash so there is less water to remove downstream.     

Recovery of ammonium lactate and removal of hardness from fermentation broth by nanofiltration

Nanofiltration (NF) was investigated as an alternative to desalting electrodialysis (ED) and ion exchange for the recovery of ammonium lactate from fermentation broth. Three commercial NF membranes, NF45, NF70, and NTR-729HF, were characterized with 50 mM NaCl, MgSO(4), and glucose solutions. NF45 membrane was selected because it showed the lowest rejection of monovalent ion, the highest rejection of divalent ion, and the highest rejection of nonpolar molecule. Effects of the operating pressure were investigated in a range of 100-400 psig, on the flux, lactate recovery, and glucose and magnesium removal from a real fermentation broth containing about 1.0 M of ammonium lactate. The flux and recovery rate increased linearly with the pressure. However, lactate rejection also increased with the pressure, lowering the recovery yield. More magnesium ions and glucose were rejected as the pressure was increased, and at 400 psig, for example, magnesium ion was almost completely rejected, highlighting the chance of obviating the necessity of ion exchange to remove hardness, by using NF instead of desalting ED. Membrane fouling was not so severe as expected, considering the complex nature and a rather high concentration of the fermentation broth treated.     

Data and knowledge based experimental design for fermentation process optimization

A novel method for the sequential experimental design in order to optimize fed-batch fermentations was applied to a hyaluronidase fermentation by Streptococcus agalactiae. A Λ-optimal design was introduced to minimize the model parameter estimation error and to maximize the performance of the fermentation process. The method employs hybrid models that contain mechanistic, fuzzy and neural network components.     

Lactose continuous fermentation with cells recycled by ultrafiltration and lactate separation by electrodialysis: model identification

Summary An off-line parameter estimation method has been developed to predict the dynamic behaviour of a continuous lactose fermentation system. The model used is an unstructured model taking into account cell growth, substrate consumption, and metabolite production (lactic acid). This method, based on the Hooke-Jeeves non-linear-programming technique, results in a good estimation of the biological parameters of the model, and so gives a better understanding of the different phenomena involved in lactose fermentation.Nomenclature Cp, Cs, Cz, Dp, Ds, Dz coefficients in system (A) - Fe bioreactor influent flow rate (1/h) - I current in the ED unit (A) - J lactate flux in the ED unit (g/h) - Kd mortality constant (h^-1) - Kp product inhibition constant (g/l) - Ks strbstrate saturation constant (g/l) - P ₀ product concentration in the bioreactor (g/l) - P ₁ product concentration in the D tank (g/l) - P _0r estimation of P ₀ (g/l) - Q ₀ retentate flow rate (UF influent) (1/h) - Q ₁ permeate flow rate (1/h) - Q ₂₂ cell bleed flow rate (1/h) - Q ₃ recycling flow rate in the ED (influent) (1/h) - Se substrate concentration in the influent (g/l) - S ₀ supstrate concentration in the bioreactor (g/l) - S ₁ substrate concentration in tank D (g/l) - S _0r estimation of S ₀ (g/l) - t time (h) - V ₀ fermentation broth volume (1) - V ₁ tank D volume (1) - X ₀ biomass concentration in the bioreactor (g/l) - Y _P/S (=1/Y _S/P) lactic acid yield coefficient (g lactic acid/g lactose consumed) - Y _X/S (=1/Y _S/X) cell yield coefficient (g cells produced/g lactose consumed) - Y _X/Z (=1/Y _Z/X) second cell yield coefficient (g cells produced/g nitrogen consumed) - Y _x, Y _m input mathematical parameters of the linear system (M ₂) - Ze nitrogen concentration in the influent (g/l) - Z ₀ nitrogen concentration in the bioreactor (g/l) - Z ₁ nitrogen concentration in tank D (g/l) - Z _0r estimation of Z ₀ (g/l) - , constants of the Luedeking and Piret's model - specific growth rate (h^-1) - _max maximum specific growth rate (h^-1)     

Yeasts strain screening method for a continuous process of alcoholic fermentation

Summary Eight different strains ofSaccharomyces cerevisiae for a continuous process of alcoholic fermentation were studied. Strains were evaluated taking into account their fermentation rate by a criterion quite different from the usual one and specific for continuous processes. It was supported on the study of strain behaviour within an ethanol concentration range equal to that existing in the continuous process.     

微生物发酵过程中连续串联系统的研究与应用

介绍了微生物发酵过程中游离细胞多级串联发酵系统的组合方式和适用范围,并对此系统的动力学模型与模拟进行了分析,最后讨论了多级串联系统的局限性。     

A continuous, farm-scale, solid-phase fermentation process for fuel ethanol and protein feed production from fodder beets

Fuel ethanol (95%) was produced from fodder beets in two farm-scale processes. In the first process, involving conventional submerged fermentation of the fodder beets in a mash, ethanol and a feed (PF) rich in protein, fat, and fiber were produced. Ethanol yields of 70 L/metric ton (7 gal/ton) were obtained; however, resulting beers had low ethanol concentrations [3-5% (v/v)]. The high viscosity of medium and low sugar, beet mashes caused mixing problems which prevented any further increase of beet sugar in the mash. The severely limited the maximum attainable ethanol concentration during fermentation, thereby making the beer costly to distill into fuel ethanol and the process energy inefficient. In order to achieve distillably worthwhile ethanol concentrations of 8-10% (v/v), we developed and tested a solid-phase fermentation process (continuous). In preliminary trials, this system produced fermented pulp with over 8% (v/v) ethanol corresponding to an ethanol yield of 87 L/metric ton (21 gal/ton). Production costs with this novel process are $0.47/L ($1.77/gal) and the energy balance is 2.11. These preliminary cost estimates indicate that fodder beets are potentially competitive with corn as an ethanol feedstock. Additional research, however, is warranted to more precisely refine individual costs, energy balances and the actual value of the PF.     

On the choice of the optimal periodic operation for a continuous fermentation process

In this contribution we investigate the impact of the forcing waveform on the productivity of a continuous bioreactor governed by an unstructured, nonlinear kinetic model. The (periodic) forcing is applied on the substrate concentration in the feed. To this end, some alternative waveforms commonly encountered in practice are evaluated and their performance is compared. An analytical/numerical approach is used. The preliminary analytical step is based on the π‐criterion that gives useful information for small amplitudes. The extension to larger amplitudes, when significant improvements are expected, is then performed through a continuation‐optimization procedure. It is found that the choice of the specific waveform has an impact on the performance of the process and there is no unique best forcing for any process condition, but its choice depends on the operating parameters and the forcing amplitude and frequency values. Further, the influence of the waveform functions on the wash‐out conditions are extensively examined. The analysis shows that all the waveforms examined in this work may lead to significant enlargement of the nontrivial regime with respect to a steady state operation. In particular, square‐wave forcing leads in practice to the extinction of the wash‐out conditions for any feed substrate concentration and for a well defined choice of the forcing parameters. © 2010 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Design of a lamella settler for biomass recycling in continuous ethanol fermentation process

The design and application of a settler to a continuous fermentation process with yeast recycle were studied. The compact lamella-type settler was chosen to avoid large volumes associated with conventional settling tanks. A rationale of the design method is covered. The sedimentation area was determined by classical batch settling rate tests and sedimentation capacity calculation. Limitations on the residence time of the microorganisms in the settler, rather than sludge thickening considerations, was the approach employed for volume calculation. Fermentation rate tests with yeast after different sedimentation periods were carried out to define a suitable residence time. Continuous cell recycle fermentation runs, performed with the old and new sedimentation devices, show that lamella settler improves biomass recycling efficiency, being the process able to operate at higher sugar concentrations and faster dilution rates.     

Acetonobutylic fermentation: improvement of performances by coupling continuous fermentation and ultrafiltration

The technology of coupling ultrafiltration and fermentation has been tested with the acetonobutylic fermentation in continuous mode. The device developed was sterilizable by steam and permitted drastic cleaning of the ultrafiltration (UF) membrane without interrupting the continuous fermentation. It has been shown to be an easily operated and reliable experimental tool for studying high-cell-density cultures and inhibition phenomena. With total recycle of biomass, a dry weight concentration of 125 g/L was attained, which greatly enhanced the volumetric solvent productivity of acetonobutylic fermentation in averaging 4. 5 g/L h for significant periods of time (>70 h) and maintaining solvent concentration and yield at acceptable levels.     

初始条件对高浓度乙醇连续发酵过程的影响及振荡行为提高发酵效率的机理分析

前期实验在稀释速率为0.027h-1的高浓度乙醇连续发酵过程中,发现了一种长周期、宽振幅的参数振荡现象。本实验进一步考察了不同稀释速率下的连续发酵过程,发现在稀释速率为0.04h-1条件下,也能出现类似的振荡现象;在稀释速率为0.027h-1或0.04h-1的条件下,改变系统的初始状态可以得到振荡和稳态两种不同的发酵过程。比较振荡和稳态过程的实验数据后,发现在稀释速率为0.04h-1的条件下,与稳态过程相比,振荡过程的平均残糖浓度降低了14.8%,平均乙醇浓度提高了12.6%,平均设备生产强度提高了12.3%。进一步分析表明:与稳态过程相比,振荡过程动力学行为不仅存在滞后,而且在相同残糖和乙醇浓度条件下,所对应的平均比生长速率提高了53.8%。     

In-situ removal of ammonium and lactate through electrical means for hybridoma cultures

Ammonium and lactate are two known toxic products detrimental to mammalian cell growth and productivity. An electrokinetic technique, utilizing an electrophoretic mechanism, was developed to remove these cellular wastes in-situ from suspension hybridoma (ATCC CRL-1606) cultures to enhance cell growth and productivity. This technique applies continuously a dc electric field to selectively remove the electrically charged wastes. The experiments were shown to be successful in the removal of externally added 10 rnM ammonium and 45 mM lactate while maintaining the chemostatic condition of culture medium in a cell-free condition under an electric current density of 50 A/m(2). Toxic levels of ammonium were added, ranging from 7.5 to 12.5 mM, at the start of the hybridoma culture, and the applied dc electric fields were able to completely remove these added materials. This in turn released the inhibition and restored the cell growth. Finally, this electrokinetic technique was applied to the batch and glutamine fed-batch hybridoma cultures. At an applied electric current density of 50 A/m(2), this was able to completely remove cell-produced ammonium and increased the cell growth and antibody titer by 30% to 50%, respectively, compared to the control experiment in the absence of the electric field. Lastly, the applied electric current density of 50 A/m(2) did not affect cellular functionalities such as glucose and glutamine consumption and antibody productivity.(c) 1995 John Wiley & Sons, Inc.